US20220190410A1 - Structural composite laminate structure for an aircraft part, aircraft part manufactured with such a laminate and aircraft - Google Patents
Structural composite laminate structure for an aircraft part, aircraft part manufactured with such a laminate and aircraft Download PDFInfo
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- US20220190410A1 US20220190410A1 US17/550,922 US202117550922A US2022190410A1 US 20220190410 A1 US20220190410 A1 US 20220190410A1 US 202117550922 A US202117550922 A US 202117550922A US 2022190410 A1 US2022190410 A1 US 2022190410A1
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- United States
- Prior art keywords
- layer
- sublayer
- structural
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- composite laminate
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- 239000002131 composite material Substances 0.000 title claims abstract description 111
- 239000000446 fuel Substances 0.000 claims abstract description 24
- 239000000835 fiber Substances 0.000 claims description 64
- 238000000926 separation method Methods 0.000 claims description 20
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 15
- 239000004917 carbon fiber Substances 0.000 claims description 15
- 239000003365 glass fiber Substances 0.000 claims description 14
- 239000012528 membrane Substances 0.000 claims description 14
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 13
- 239000003792 electrolyte Substances 0.000 claims description 12
- 239000003054 catalyst Substances 0.000 claims description 9
- 229910052751 metal Inorganic materials 0.000 claims description 8
- 239000002184 metal Substances 0.000 claims description 8
- 239000000463 material Substances 0.000 claims description 7
- 238000000034 method Methods 0.000 claims description 6
- 238000003860 storage Methods 0.000 claims description 6
- 238000009792 diffusion process Methods 0.000 claims description 5
- 238000006243 chemical reaction Methods 0.000 claims description 3
- 239000012530 fluid Substances 0.000 claims description 2
- 230000036647 reaction Effects 0.000 claims description 2
- 239000007789 gas Substances 0.000 description 32
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 8
- 230000008901 benefit Effects 0.000 description 6
- 239000004918 carbon fiber reinforced polymer Substances 0.000 description 5
- 238000009413 insulation Methods 0.000 description 4
- 230000010354 integration Effects 0.000 description 4
- 229910052697 platinum Inorganic materials 0.000 description 4
- 239000005518 polymer electrolyte Substances 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- 229910052799 carbon Inorganic materials 0.000 description 3
- 229910052802 copper Inorganic materials 0.000 description 3
- 239000010949 copper Substances 0.000 description 3
- 238000004146 energy storage Methods 0.000 description 3
- 239000001301 oxygen Substances 0.000 description 3
- 229910052760 oxygen Inorganic materials 0.000 description 3
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 150000001879 copper Chemical class 0.000 description 2
- 239000003733 fiber-reinforced composite Substances 0.000 description 2
- 239000001257 hydrogen Substances 0.000 description 2
- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 230000007774 longterm Effects 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 230000000295 complement effect Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000005315 distribution function Methods 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 229910052707 ruthenium Inorganic materials 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
Images
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Definitions
- the invention relates to a structural composite laminate structure for an aircraft component.
- the invention further relates to an aircraft component and an aircraft comprising such a structural composite laminate structure.
- U.S. Pat. No. 9,520,580 B2 discloses an electrochemical appliance installed in a composite component.
- the invention provides a structural composite laminate structure for an aircraft component, in particular a self-supporting primary structural component, of an aircraft, wherein the composite laminate structure comprises a plurality of structural layer structures stacked on top of one another, namely
- the fiber composite layer structure preferably has an outer fiber composite layer region which is arranged on an outside of the composite laminate structure, which forms an outer skin, and which is applied to the energy generation layer structure.
- the fiber composite layer structure preferably has an integrated fiber composite layer region which is arranged as fiber composite intermediate layer between the energy generation layer structure and the supercapacitor layer structure.
- the fiber composite layer structure preferably comprises an insulating fiber composite layer which is applied to the energy generation layer structure.
- the outer fiber composite layer region preferably comprises a plurality of outer fiber composite layer sublayers, where a part of the fiber composite layer sublayers facing the energy generation layer structure is made of insulating glass fiber sublayers in order to form an insulating fiber composite layer.
- the outer fiber composite layer region preferably comprises a plurality of outer fiber composite layer sublayers, where a part of the fiber composite layer sublayers facing away from the energy generation layer is made of carbon fiber sublayers.
- the integrated fiber composite layer region preferably comprises a plurality of outer fiber composite layer sublayers, where a part of the fiber composite layer sublayers facing the energy generation layer structure is made of insulating glass fiber sublayers in order to form an insulating fiber composite layer.
- the integrated fiber composite layer region preferably comprises a plurality of outer fiber composite layer sublayers, where a part of the fiber composite layer sublayers facing away from the energy generation layer is made of carbon fiber sublayers.
- the energy generation layer structure preferably comprises an ion-conducting separation layer, a first gas distributor layer and a second gas distributor layer, which each adjoin the ion-conducting separation layer and distribute gas in a layer plane, and an electrically conductive cathode layer, which adjoins the first gas distributor layer, and an electrically conductive anode layer, which adjoins the second gas distributor layer.
- the ion-conducting separation layer preferably comprises a plurality of separation layer sublayers, where one separation layer sublayer is a proton exchange membrane and at least one separation layer sublayer applied to the proton exchange membrane is a catalyst membrane coated with a catalyst suitable for a fuel cell reaction.
- the first gas distributor layer and/or the second gas distributor layer preferably comprise a plurality of gas distributor sublayers, where a part of the gas distributor sublayers facing away from the ion-conducting separation layer forms a gas diffusion sublayer and/or where a part of the gas distributor sublayers applied to the ion-conducting separation layer forms a microperforated sublayer.
- the cathode layer and/or the anode layer preferably have a plurality of bipolar plate sublayers and current collector sublayers, where each bipolar plate sublayer is a composite sublayer, preferably carbon composite sublayer, which contains at least one gas channel and/or where each current collector sublayer is a composite sublayer containing a metal.
- the supercapacitor layer structure preferably comprises a first current collector layer and a second current collector layer between which a supercapacitor layer is arranged, where the first current collector layer is applied adjoining the energy generation layer structure and where the second current collector layer is applied adjoining the battery layer structure.
- the first current collector layer and/or the second current collector layer preferably contains an electrode sublayer which is composed of carbon fibers and is applied to the supercapacitor layer.
- the supercapacitor layer preferably comprises a plurality of electrolyte sublayers, preferably composed of a polymer electrolyte, where at least two electrolyte sublayers are each applied separately from one another to the first current collector layer and to the second current collector layer, and at least one separator sublayer, preferably composed of insulating glass fiber composite material, where the separator sublayer electrically insulates at least two electrolyte sublayers from one another and is applied to these.
- One of the current collector layers preferably comprises a current collector sublayer which contains metal and is applied adjoining the fiber composite layer structure, preferably to the integrated fiber composite layer region.
- the battery layer structure preferably comprises a battery layer which comprises a negative electrode sublayer and a positive electrode sublayer which are separated from one another by a separator sublayer, where each sublayer of the battery layer contains a structural electrolyte.
- the battery layer structure preferably comprises a plurality of current collector sublayers which are each applied to the negative electrode sublayer and the positive electrode sublayer and/or where the battery layer structure comprises an insulating glass fiber separator which separates the battery layer structure from the supercapacitor layer structure and is applied thereto.
- the composite laminate structure preferably comprises an integrated control unit which is configured for controlling the generation, storage and retrieval of electric energy by the energy generation layer structure, the supercapacitor layer structure and the battery layer structure, where the control unit is electrically conductively connected to these layer structures and where the control unit is fluidically connected to the energy generation layer structure in order to introduce and discharge fluids.
- an integrated control unit which is configured for controlling the generation, storage and retrieval of electric energy by the energy generation layer structure, the supercapacitor layer structure and the battery layer structure, where the control unit is electrically conductively connected to these layer structures and where the control unit is fluidically connected to the energy generation layer structure in order to introduce and discharge fluids.
- the invention provides an aircraft component, preferably exterior panel, for an aircraft, where the aircraft component is made of a composite laminate comprising a composite laminate structure as described above.
- the invention further provides an aircraft containing at least one such aircraft component.
- the invention provides a process for producing an energy generation layer structure for a composite laminate structure, wherein the energy generation layer structure is formed by laying down fiber sublayers, where the first gas distributor layer or the second gas distributor layer is formed by laying down carbon fiber sublayers in which a gas channel has been formed by removal of material, preferably removal of material by laser.
- One idea is to create an improved structural fuel cell which is integrated into a structural laminate.
- the fuel cell is combined with a structural battery laminate and a supercapacitor laminate in a single part in order to combine the advantages of the structural fuel cell, the structural battery and the structural supercapacitor and avoid the individual disadvantages thereof
- fuel cells can be integrated better into primary structures or aircraft cells of aircraft and spacecraft together with structural battery laminates and structural supercapacitors.
- the various complementary functions of generation, storage and (more rapid) retrieval of stored electricity can be integrated into the aircraft cell or spacecraft cell, which makes a lighter-weight solution in the overall system possible.
- the ideas explained herein are generally applicable to aircraft. It is ultimately an objective of these measures to reduce emissions during air travel and thus also reduce the environmental footprint.
- the advantages of the battery are combined with those of the supercapacitor, with the advantages of the structural fuel cell at the same time being combined with the advantages of the structural laminate.
- the structural laminate is usually a carbon fiber-reinforced composite (carbon fiber reinforced plastic, CFRP).
- an electric energy generation function can be obtained by means of hydrogen and oxygen from the CFRP laminate.
- the integration of the energy source or the energy generator into the structure of the aircraft or spacecraft makes it possible to avoid complicated cable connections. Furthermore, resistance losses can be greatly decreased.
- the composite laminate structure has a number of functions: structural function, energy supply, passive cooling due to a large surface area.
- the fuel cell layers do not require separate cables or wires. Furthermore, the system does not have to be separately integrated into the primary structural laminate. As a consequence, cable clamps or conduits are also no longer necessary.
- the structural fuel cell can have improved power and efficiency because of the integration.
- the fuel cells can be produced more simply; they have fewer components and are formed directly by sublayers of the structural laminate.
- the integration also allows a weight and cost saving. A greater structural efficiency of the overall system is likewise possible as a result of the functional integration into a laminate or panel.
- the composite laminate and the corresponding regions can be charged and discharged quickly. It has a long life and high fatigue resistance. Furthermore, the energy density and also the power density can be increased.
- the structural supercapacitor sublayers allow a rapid reaction, while long-term storage capability is ensured by the structural batteries.
- the energy generation sublayers and the energy storage sublayers are arranged in a sandwich structure together with structural CFRP sublayers and form a combined structural battery having a structural supercapacitor and a structural fuel cell in a laminate, in order to form a multifunctional laminate for energy storage and energy supply.
- the structural supercapacitor layers in the structural laminate provide the capability of storing a useful amount of energy for a comparatively short period of time (from a few seconds to a few minutes).
- the supercapacitor layers function as energy reservoirs which assist the function of the structural battery. Peaks in demand from electric and electronic components can thus be moderated.
- the supercapacitor layers are joined to the structural battery layers in order to regulate the energy supply, and also connected to the structural fuel cell which generates electric energy from the fuel cell process.
- FIG. 1 is a working example of an aircraft
- FIG. 2 is a working example of a composite laminate
- FIG. 3 is a detailed view of an energy generation layer structure
- FIG. 4 is a detailed view of a supercapacitor layer structure
- FIG. 5 is a detailed view of a battery layer structure
- FIG. 6 is a depiction of the energy supply to aircraft components
- FIG. 7 is a variant of the energy supply to aircraft components.
- FIGS. 8A and 8B are a working example of a process for producing a composite laminate structure.
- FIG. 1 shows a working example of an aircraft 10 .
- the aircraft 10 comprises a fuselage structure 12 to which a pair of wings 14 are attached. At least one engine nacelle 16 is preferably attached to each wing 14 . Furthermore, the aircraft 10 has a tailplane 18 , the configuration of which is known per se.
- the fuselage structure 12 , the wings 14 , the engine nacelle 16 and the tailplane 18 are made predominantly of a composite laminate structure 20 .
- the abovementioned regions can each be made of one or more exterior panels 22 which contain the composite laminate structure 20 .
- FIG. 2 depicts the overall structure of the composite laminate structure 20
- FIG. 3 depicts the overall structure of the composite laminate structure 20
- the structural composite laminate structure 20 contains a plurality of likewise structural layer structures which are each stacked on top of one another.
- the composite laminate structure 20 contains a structural fiber composite layer structure 24 .
- the fiber composite layer structure 24 has an outer fiber composite region 26 and an integrated fiber composite region 28 .
- the composite laminate structure 20 contains an energy generation layer structure 30 which is embedded in the fiber composite layer structure 24 .
- the energy generation layer structure 30 is arranged between the outer fiber composite region 26 and the integrated fiber composite region 28 and joined thereto.
- the outer fiber composite region 26 and the integrated fiber composite region 28 preferably have an identical configuration.
- Each fiber composite region 26 , 28 preferably comprises a plurality of carbon fiber sublayers 32 and a plurality of glass fiber insulation sublayers 34 .
- the carbon fiber sublayers 32 and the glass fiber insulation sublayers 34 are stacked on top of one another in such a way that the respective glass fiber insulation layer 34 faces the energy generation layer structure 30 and is applied thereto, while the carbon fiber sublayers 32 adjoin the glass fiber insulation sublayers 34 .
- the energy generation layer structure 30 comprises an ion-conducting separation layer 36 , a first gas distributor layer 38 and a second gas distributor layer 40 .
- the ion-conducting separation layer 36 is arranged between the first and second gas distributor layers 38 , 40 .
- a cathode layer 42 is arranged adjoining the first gas distributor layer 38 .
- An anode layer 44 is arranged adjoining the second gas distributor layer 40 .
- the ion-conducting separation layer 36 comprises at least one proton exchange membrane 46 and a catalyst membrane 48 on each side of the proton exchange membrane 46 .
- the proton exchange membrane 46 contains a polymer electrolyte known per se.
- the catalyst membrane 48 preferably contains platinum or a mixture of platinum and ruthenium, platinum and nickel or platinum and cobalt, which are usually employed in hydrogen-oxygen fuel cells, as a catalyst.
- the first gas distributor layer 38 and the second gas distributor layer 40 preferably have an identical structure and contain a microporous structural sublayer 50 and a gas diffusion sublayer 52 .
- the microporous structural sublayer 50 adjoins the catalyst membrane 48 .
- the gas diffusion sublayer 52 has been applied to the microporous structural sublayer 50 and adjoins the cathode layer 42 or the anode layer 44 .
- the cathode layer 42 and the anode layer 44 have an essentially identical configuration.
- the cathode layer 52 contains bipolar plate sublayers 54 .
- the bipolar plate sublayer 54 is, for example, made of carbon fiber-reinforced polymer and contains a gas channel 56 which has been structured by removal of material by laser.
- the cathode layer 42 and the anode layer 44 contains a current collector sublayer 58 .
- the current collector sublayer 58 serves to electrically connect the energy generation layer structure to a control unit (will be described in more detail) and can contain a metal, for example copper in the form of a copper braid.
- the composite laminate structure 20 contains a supercapacitor layer structure 60 .
- the supercapacitor layer structure is likewise configured as structural layer structure and is applied to the fiber composite layer structure 24 .
- the supercapacitor layer structure 60 contains a supercapacitor layer 62 , a first current collector layer 64 and a second current collector layer 66 .
- the supercapacitor layer 62 is arranged between the first and second current collector layers 64 , 66 .
- the supercapacitor layer 62 contains at least one separator sublayer 68 composed of a glass fiber material.
- the supercapacitor layer 62 contains a plurality of electrolyte sublayers 70 which are arranged on the two sides of the separator sublayer 68 .
- the electrolyte sublayer 70 contains a solid polymer electrolyte, which is known per se.
- the first current collector layer 64 adjoins one of the electrolyte sublayers 70 and contains a structural carbon fiber electrode 72 . Furthermore, the first current collector layer 64 contains a structural current collector 74 .
- the current collector 74 preferably contains a metal, for example in the form of a copper braid, and can be connected to a control unit or controller.
- the second current collector layer 66 likewise contains a carbon fiber electrode 76 .
- the carbon fiber electrode 76 is likewise able to be connected to a control unit.
- the second current collector layer 66 can, in one variant, likewise comprise a metal-containing current collector.
- the composite laminate structure 20 additionally contains a structural battery layer structure 80 .
- the battery layer structure 80 contains a glass fiber separator 82 which separates the battery layer structure 80 from the supercapacitor layer structure 60 . Furthermore, the battery layer structure 80 contains a battery layer 84 .
- the battery layer 84 comprises a negative electrode sublayer 86 and a positive electrode sublayer 88 . Both the negative electrode sublayer 86 and the positive electrode sublayer 88 are made of a carbon fiber-reinforced composite.
- the negative electrode sublayer 86 and the positive electrode sublayer 88 are separated by a separator sublayer 90 which is made of glass fibers.
- Each sublayer in the battery layer 84 contains a solid polymer electrolyte.
- the battery layer structure 80 additionally contains two current collector sublayers 92 which can contain a metal braid.
- the current collector sublayers 92 can be connected to a control unit.
- the composite laminate structure 20 additionally contains a control unit or controller 94 .
- the control unit 94 can be a microcontroller which controls power generation, power storage and power retrieval from the composite laminate structure 20 .
- the control unit 94 is furthermore responsible for supplying the energy generation layer structure 30 with hydrogen and oxygen for energy production.
- the control unit 94 is, in particular, configured as flat integrated microcontroller which can, for example, be applied at the side of the composite laminate structure.
- the control unit 94 can also provide connections for diagnostic purposes or supply purposes.
- the power uptake of the aircraft 10 can have a plurality of power peaks 98 in addition to the base load 96 . Both the base load 96 and the power peaks 98 are provided by the structural battery.
- the control unit 94 in this case controls the power offtake from the structural battery.
- the base load 96 is provided by the structural battery while the power peaks 98 are provided by the structural supercapacitor.
- the control unit 94 controls these correspondingly.
- control unit 94 supplies the energy generation layer structure 30 with gases and controls this structure in such a way that a sufficient quantity of energy is stored in the structural battery or the structural supercapacitor during the duration of normal operation.
- FIGS. 8A and 8B schematically shows a working example of a process for producing the composite laminate structure 20 .
- individual fiber sublayers 100 can be structured by means of a laser structuring unit 102 .
- the fiber sublayer 100 has a usual thickness of from 0.1 mm to 0.3 mm.
- a robotic arm 104 can direct a laser beam 108 produced by a laser apparatus 106 onto the fiber sublayer 100 for the purpose of removing material and can thus create a meandering gas channel 110 .
- the composite laminate structure 20 is produced by laying down fiber tapes 112 or fiber sublayers ( FIG. 8B ), e.g., the fiber sublayers 100 , using an appropriate fiber laying machine 114 .
- the fiber sublayers 100 can be laid down onto the existing part of the composite laminate structure 20 in order to produce part of the energy generation layer structure 30 .
- the aircraft component has an energy generation function, an energy storage function and an energy distribution function.
- a composite laminate structure 20 which contains a structural fuel cell 30 , a structural supercapacitor 60 and a structural battery 80 is provided by means of the above-described measures.
- Each one of the components 30 , 60 , 80 has a self-supporting configuration so that aircraft components, for example exterior panels 22 , can be produced therefrom.
- the aircraft components are able to generate electric energy by means of the structural fuel cell 30 and distribute it over the entire aircraft 10 without cables.
- short-term power peaks 98 can be supplied by the structural supercapacitor 60 , while the base load 96 is supplied by the structural battery 80 .
Abstract
Description
- This application claims the benefit of the German patent application No. 102020133854.6 filed on Dec. 16, 2020, the entire disclosures of which are incorporated herein by way of reference.
- The invention relates to a structural composite laminate structure for an aircraft component. The invention further relates to an aircraft component and an aircraft comprising such a structural composite laminate structure.
- U.S. Pat. No. 9,520,580 B2 discloses an electrochemical appliance installed in a composite component.
- It is an object of the invention to integrate a structural fuel cell, a structural battery and a structural supercapacitor into the same component of an aircraft cell.
- The invention provides a structural composite laminate structure for an aircraft component, in particular a self-supporting primary structural component, of an aircraft, wherein the composite laminate structure comprises a plurality of structural layer structures stacked on top of one another, namely
-
- a structural fiber composite layer structure made of a fiber composite material;
- a structural energy generation layer structure which forms a fuel cell, and which is applied to the fiber composite layer structure;
- a structural supercapacitor layer structure which forms a supercapacitor; and
- a structural battery layer structure which forms a structural battery, and which is applied to the supercapacitor layer structure.
- The fiber composite layer structure preferably has an outer fiber composite layer region which is arranged on an outside of the composite laminate structure, which forms an outer skin, and which is applied to the energy generation layer structure.
- The fiber composite layer structure preferably has an integrated fiber composite layer region which is arranged as fiber composite intermediate layer between the energy generation layer structure and the supercapacitor layer structure.
- The fiber composite layer structure preferably comprises an insulating fiber composite layer which is applied to the energy generation layer structure.
- The outer fiber composite layer region preferably comprises a plurality of outer fiber composite layer sublayers, where a part of the fiber composite layer sublayers facing the energy generation layer structure is made of insulating glass fiber sublayers in order to form an insulating fiber composite layer.
- The outer fiber composite layer region preferably comprises a plurality of outer fiber composite layer sublayers, where a part of the fiber composite layer sublayers facing away from the energy generation layer is made of carbon fiber sublayers.
- The integrated fiber composite layer region preferably comprises a plurality of outer fiber composite layer sublayers, where a part of the fiber composite layer sublayers facing the energy generation layer structure is made of insulating glass fiber sublayers in order to form an insulating fiber composite layer.
- The integrated fiber composite layer region preferably comprises a plurality of outer fiber composite layer sublayers, where a part of the fiber composite layer sublayers facing away from the energy generation layer is made of carbon fiber sublayers.
- The energy generation layer structure preferably comprises an ion-conducting separation layer, a first gas distributor layer and a second gas distributor layer, which each adjoin the ion-conducting separation layer and distribute gas in a layer plane, and an electrically conductive cathode layer, which adjoins the first gas distributor layer, and an electrically conductive anode layer, which adjoins the second gas distributor layer.
- The ion-conducting separation layer preferably comprises a plurality of separation layer sublayers, where one separation layer sublayer is a proton exchange membrane and at least one separation layer sublayer applied to the proton exchange membrane is a catalyst membrane coated with a catalyst suitable for a fuel cell reaction.
- The first gas distributor layer and/or the second gas distributor layer preferably comprise a plurality of gas distributor sublayers, where a part of the gas distributor sublayers facing away from the ion-conducting separation layer forms a gas diffusion sublayer and/or where a part of the gas distributor sublayers applied to the ion-conducting separation layer forms a microperforated sublayer.
- The cathode layer and/or the anode layer preferably have a plurality of bipolar plate sublayers and current collector sublayers, where each bipolar plate sublayer is a composite sublayer, preferably carbon composite sublayer, which contains at least one gas channel and/or where each current collector sublayer is a composite sublayer containing a metal.
- The supercapacitor layer structure preferably comprises a first current collector layer and a second current collector layer between which a supercapacitor layer is arranged, where the first current collector layer is applied adjoining the energy generation layer structure and where the second current collector layer is applied adjoining the battery layer structure.
- The first current collector layer and/or the second current collector layer preferably contains an electrode sublayer which is composed of carbon fibers and is applied to the supercapacitor layer.
- The supercapacitor layer preferably comprises a plurality of electrolyte sublayers, preferably composed of a polymer electrolyte, where at least two electrolyte sublayers are each applied separately from one another to the first current collector layer and to the second current collector layer, and at least one separator sublayer, preferably composed of insulating glass fiber composite material, where the separator sublayer electrically insulates at least two electrolyte sublayers from one another and is applied to these.
- One of the current collector layers preferably comprises a current collector sublayer which contains metal and is applied adjoining the fiber composite layer structure, preferably to the integrated fiber composite layer region.
- The battery layer structure preferably comprises a battery layer which comprises a negative electrode sublayer and a positive electrode sublayer which are separated from one another by a separator sublayer, where each sublayer of the battery layer contains a structural electrolyte.
- The battery layer structure preferably comprises a plurality of current collector sublayers which are each applied to the negative electrode sublayer and the positive electrode sublayer and/or where the battery layer structure comprises an insulating glass fiber separator which separates the battery layer structure from the supercapacitor layer structure and is applied thereto.
- The composite laminate structure preferably comprises an integrated control unit which is configured for controlling the generation, storage and retrieval of electric energy by the energy generation layer structure, the supercapacitor layer structure and the battery layer structure, where the control unit is electrically conductively connected to these layer structures and where the control unit is fluidically connected to the energy generation layer structure in order to introduce and discharge fluids.
- The invention provides an aircraft component, preferably exterior panel, for an aircraft, where the aircraft component is made of a composite laminate comprising a composite laminate structure as described above.
- The invention further provides an aircraft containing at least one such aircraft component.
- The invention provides a process for producing an energy generation layer structure for a composite laminate structure, wherein the energy generation layer structure is formed by laying down fiber sublayers, where the first gas distributor layer or the second gas distributor layer is formed by laying down carbon fiber sublayers in which a gas channel has been formed by removal of material, preferably removal of material by laser.
- One idea is to create an improved structural fuel cell which is integrated into a structural laminate. The fuel cell is combined with a structural battery laminate and a supercapacitor laminate in a single part in order to combine the advantages of the structural fuel cell, the structural battery and the structural supercapacitor and avoid the individual disadvantages thereof
- On the basis of the ideas described herein, fuel cells can be integrated better into primary structures or aircraft cells of aircraft and spacecraft together with structural battery laminates and structural supercapacitors. In this way, the various complementary functions of generation, storage and (more rapid) retrieval of stored electricity can be integrated into the aircraft cell or spacecraft cell, which makes a lighter-weight solution in the overall system possible. The ideas explained herein are generally applicable to aircraft. It is ultimately an objective of these measures to reduce emissions during air travel and thus also reduce the environmental footprint.
- The advantages of the battery are combined with those of the supercapacitor, with the advantages of the structural fuel cell at the same time being combined with the advantages of the structural laminate. The structural laminate is usually a carbon fiber-reinforced composite (carbon fiber reinforced plastic, CFRP).
- Due to the fuel cell, an electric energy generation function can be obtained by means of hydrogen and oxygen from the CFRP laminate. The integration of the energy source or the energy generator into the structure of the aircraft or spacecraft makes it possible to avoid complicated cable connections. Furthermore, resistance losses can be greatly decreased.
- The composite laminate structure has a number of functions: structural function, energy supply, passive cooling due to a large surface area.
- The fuel cell layers do not require separate cables or wires. Furthermore, the system does not have to be separately integrated into the primary structural laminate. As a consequence, cable clamps or conduits are also no longer necessary.
- No separate installation work arises as a result of the invention because manual installation can be dispensed with. Furthermore, no additional housings or structures are necessary because the energy supply and the control unit are integrated in a single part.
- In addition, the structural fuel cell can have improved power and efficiency because of the integration. The fuel cells can be produced more simply; they have fewer components and are formed directly by sublayers of the structural laminate.
- Faster production is thus also possible. The integration also allows a weight and cost saving. A greater structural efficiency of the overall system is likewise possible as a result of the functional integration into a laminate or panel.
- The composite laminate and the corresponding regions can be charged and discharged quickly. It has a long life and high fatigue resistance. Furthermore, the energy density and also the power density can be increased.
- The structural supercapacitor sublayers allow a rapid reaction, while long-term storage capability is ensured by the structural batteries. The energy generation sublayers and the energy storage sublayers are arranged in a sandwich structure together with structural CFRP sublayers and form a combined structural battery having a structural supercapacitor and a structural fuel cell in a laminate, in order to form a multifunctional laminate for energy storage and energy supply.
- When energy consumers such as heating, engine and the like are switched on, energy peaks usually arise. The current and voltage peaks can be provided more readily by supercapacitors, while long-term storage is provided by the structural battery. Energy generation is effected by the structural fuel cell. All layers of the multifunctional laminate provide a load-bearing function.
- The structural supercapacitor layers in the structural laminate provide the capability of storing a useful amount of energy for a comparatively short period of time (from a few seconds to a few minutes). The supercapacitor layers function as energy reservoirs which assist the function of the structural battery. Peaks in demand from electric and electronic components can thus be moderated.
- The supercapacitor layers are joined to the structural battery layers in order to regulate the energy supply, and also connected to the structural fuel cell which generates electric energy from the fuel cell process.
- Working examples will be explained in more detail with the aid of the accompanying schematic drawings. The drawings show:
-
FIG. 1 is a working example of an aircraft; -
FIG. 2 is a working example of a composite laminate; -
FIG. 3 is a detailed view of an energy generation layer structure; -
FIG. 4 is a detailed view of a supercapacitor layer structure; -
FIG. 5 is a detailed view of a battery layer structure; -
FIG. 6 is a depiction of the energy supply to aircraft components; -
FIG. 7 is a variant of the energy supply to aircraft components; and -
FIGS. 8A and 8B are a working example of a process for producing a composite laminate structure. - Reference is made below to
FIG. 1 which shows a working example of anaircraft 10. Theaircraft 10 comprises a fuselage structure 12 to which a pair ofwings 14 are attached. At least oneengine nacelle 16 is preferably attached to eachwing 14. Furthermore, theaircraft 10 has atailplane 18, the configuration of which is known per se. - In the present case, the fuselage structure 12, the
wings 14, theengine nacelle 16 and thetailplane 18 are made predominantly of acomposite laminate structure 20. - Here, the abovementioned regions can each be made of one or more
exterior panels 22 which contain thecomposite laminate structure 20. - Reference is made below to
FIG. 2 , which depicts the overall structure of thecomposite laminate structure 20, andFIG. 3 . The structuralcomposite laminate structure 20 contains a plurality of likewise structural layer structures which are each stacked on top of one another. - The
composite laminate structure 20 contains a structural fibercomposite layer structure 24. The fibercomposite layer structure 24 has an outerfiber composite region 26 and an integratedfiber composite region 28. - The
composite laminate structure 20 contains an energygeneration layer structure 30 which is embedded in the fibercomposite layer structure 24. In other words, the energygeneration layer structure 30 is arranged between the outerfiber composite region 26 and the integratedfiber composite region 28 and joined thereto. - The outer
fiber composite region 26 and the integratedfiber composite region 28 preferably have an identical configuration. Eachfiber composite region carbon fiber sublayers 32 and a plurality of glassfiber insulation sublayers 34. Thecarbon fiber sublayers 32 and the glassfiber insulation sublayers 34 are stacked on top of one another in such a way that the respective glassfiber insulation layer 34 faces the energygeneration layer structure 30 and is applied thereto, while thecarbon fiber sublayers 32 adjoin the glassfiber insulation sublayers 34. - The energy
generation layer structure 30 comprises an ion-conducting separation layer 36, a firstgas distributor layer 38 and a secondgas distributor layer 40. The ion-conducting separation layer 36 is arranged between the first and second gas distributor layers 38, 40. Acathode layer 42 is arranged adjoining the firstgas distributor layer 38. Ananode layer 44 is arranged adjoining the secondgas distributor layer 40. - The ion-conducting separation layer 36 comprises at least one proton exchange membrane 46 and a
catalyst membrane 48 on each side of the proton exchange membrane 46. - The proton exchange membrane 46 contains a polymer electrolyte known per se.
- The
catalyst membrane 48 preferably contains platinum or a mixture of platinum and ruthenium, platinum and nickel or platinum and cobalt, which are usually employed in hydrogen-oxygen fuel cells, as a catalyst. - The first
gas distributor layer 38 and the secondgas distributor layer 40 preferably have an identical structure and contain a microporous structural sublayer 50 and agas diffusion sublayer 52. The microporous structural sublayer 50 adjoins thecatalyst membrane 48. Thegas diffusion sublayer 52 has been applied to the microporous structural sublayer 50 and adjoins thecathode layer 42 or theanode layer 44. - The
cathode layer 42 and theanode layer 44 have an essentially identical configuration. - The
cathode layer 52 containsbipolar plate sublayers 54. Thebipolar plate sublayer 54 is, for example, made of carbon fiber-reinforced polymer and contains agas channel 56 which has been structured by removal of material by laser. - Furthermore, the
cathode layer 42 and theanode layer 44 contains acurrent collector sublayer 58. Thecurrent collector sublayer 58 serves to electrically connect the energy generation layer structure to a control unit (will be described in more detail) and can contain a metal, for example copper in the form of a copper braid. - Reference will be made below to
FIG. 2 andFIG. 4 . Thecomposite laminate structure 20 contains asupercapacitor layer structure 60. The supercapacitor layer structure is likewise configured as structural layer structure and is applied to the fibercomposite layer structure 24. - The
supercapacitor layer structure 60 contains a supercapacitor layer 62, a firstcurrent collector layer 64 and a secondcurrent collector layer 66. The supercapacitor layer 62 is arranged between the first and second current collector layers 64, 66. The supercapacitor layer 62 contains at least one separator sublayer 68 composed of a glass fiber material. The supercapacitor layer 62 contains a plurality ofelectrolyte sublayers 70 which are arranged on the two sides of the separator sublayer 68. Theelectrolyte sublayer 70 contains a solid polymer electrolyte, which is known per se. - The first
current collector layer 64 adjoins one of the electrolyte sublayers 70 and contains a structural carbon fiber electrode 72. Furthermore, the firstcurrent collector layer 64 contains a structuralcurrent collector 74. Thecurrent collector 74 preferably contains a metal, for example in the form of a copper braid, and can be connected to a control unit or controller. - The second
current collector layer 66 likewise contains acarbon fiber electrode 76. Thecarbon fiber electrode 76 is likewise able to be connected to a control unit. The secondcurrent collector layer 66 can, in one variant, likewise comprise a metal-containing current collector. - Reference will be made below to
FIG. 2 andFIG. 5 . Thecomposite laminate structure 20 additionally contains a structuralbattery layer structure 80. - The
battery layer structure 80 contains aglass fiber separator 82 which separates thebattery layer structure 80 from thesupercapacitor layer structure 60. Furthermore, thebattery layer structure 80 contains abattery layer 84. Thebattery layer 84 comprises anegative electrode sublayer 86 and apositive electrode sublayer 88. Both thenegative electrode sublayer 86 and thepositive electrode sublayer 88 are made of a carbon fiber-reinforced composite. Thenegative electrode sublayer 86 and thepositive electrode sublayer 88 are separated by aseparator sublayer 90 which is made of glass fibers. Each sublayer in thebattery layer 84 contains a solid polymer electrolyte. - The
battery layer structure 80 additionally contains twocurrent collector sublayers 92 which can contain a metal braid. Thecurrent collector sublayers 92 can be connected to a control unit. - The
composite laminate structure 20 additionally contains a control unit orcontroller 94. Thecontrol unit 94 can be a microcontroller which controls power generation, power storage and power retrieval from thecomposite laminate structure 20. Thecontrol unit 94 is furthermore responsible for supplying the energygeneration layer structure 30 with hydrogen and oxygen for energy production. Thecontrol unit 94 is, in particular, configured as flat integrated microcontroller which can, for example, be applied at the side of the composite laminate structure. Thecontrol unit 94 can also provide connections for diagnostic purposes or supply purposes. - Possible energy supply scenarios will be described in more detail below with reference to
FIG. 6 andFIG. 7 . - As depicted in
FIG. 6 , the power uptake of theaircraft 10 can have a plurality ofpower peaks 98 in addition to thebase load 96. Both thebase load 96 and the power peaks 98 are provided by the structural battery. Thecontrol unit 94 in this case controls the power offtake from the structural battery. - In contrast thereto, as depicted in
FIG. 7 , thebase load 96 is provided by the structural battery while the power peaks 98 are provided by the structural supercapacitor. Thecontrol unit 94 controls these correspondingly. - It should be noted that for longer-term energy supply, the
control unit 94 supplies the energygeneration layer structure 30 with gases and controls this structure in such a way that a sufficient quantity of energy is stored in the structural battery or the structural supercapacitor during the duration of normal operation. - Reference will be made below to
FIGS. 8A and 8B which schematically shows a working example of a process for producing thecomposite laminate structure 20. - Firstly (
FIG. 8A ),individual fiber sublayers 100 can be structured by means of alaser structuring unit 102. Thefiber sublayer 100 has a usual thickness of from 0.1 mm to 0.3 mm. Arobotic arm 104 can direct a laser beam 108 produced by alaser apparatus 106 onto thefiber sublayer 100 for the purpose of removing material and can thus create a meanderinggas channel 110. - The
composite laminate structure 20 is produced by laying downfiber tapes 112 or fiber sublayers (FIG. 8B ), e.g., thefiber sublayers 100, using an appropriatefiber laying machine 114. For example, thefiber sublayers 100 can be laid down onto the existing part of thecomposite laminate structure 20 in order to produce part of the energygeneration layer structure 30. - After the layer-by-layer laying down of the entire
composite laminate structure 20, the latter is consolidated in an autoclave so as to form an aircraft component, for example anexterior panel 22. The aircraft component has an energy generation function, an energy storage function and an energy distribution function. - A
composite laminate structure 20 which contains astructural fuel cell 30, astructural supercapacitor 60 and astructural battery 80 is provided by means of the above-described measures. Each one of thecomponents example exterior panels 22, can be produced therefrom. The aircraft components are able to generate electric energy by means of thestructural fuel cell 30 and distribute it over theentire aircraft 10 without cables. Furthermore, short-term power peaks 98 can be supplied by thestructural supercapacitor 60, while thebase load 96 is supplied by thestructural battery 80. - While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms “comprise” or “comprising” do not exclude other elements or steps, the terms “a” or “one” do not exclude a plural number, and the term “or” means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.
-
- 10 Aircraft
- 12 Fuselage structure
- 14 Wing
- 16 Engine nacelle
- 18 Tailplane
- 20 Composite laminate structure
- 22 Exterior panel
- 24 Fiber composite layer structure
- 26 Outer fiber composite region
- 28 Integrated fiber composite region
- 30 Energy generation layer structure (fuel cell)
- 32 Carbon fiber sublayer
- 34 Glass fiber insulating sublayer
- 36 Ion-conducting separation layer
- 38 First gas distributor layer
- 40 Second gas distributor layer
- 42 Cathode layer
- 44 Anode layer
- 46 Proton exchange membrane
- 48 Catalyst membrane
- 50 Microporous structural sublayer
- 52 Gas diffusion sublayer
- 54 Bipolar plate sublayer
- 56 Gas channel
- 58 Current collector sublayer
- 60 Supercapacitor layer structure
- 62 Supercapacitor layer
- 64 First current collector layer
- 66 Second current collector layer
- 68 Separator sublayer
- 70 Electrolyte sublayer
- 72 Carbon fiber electrode
- 74 Current collector
- 76 Carbon fiber electrode
- 80 Battery layer structure
- 82 Glass fiber separator
- 84 Battery layer
- 86 Negative electrode sublayer
- 88 Positive electrode sublayer
- 90 Separator sublayer
- 92 Current collector sublayers
- 94 Control unit/controller
- 96 Base load
- 98 Power peak
- 100 Fiber sublayer
- 102 Laser structuring unit
- 104 Robotic arm
- 106 Laser apparatus
- 108 Laser beam
- 110 Gas channel
- 112 Fiber tape
- 114 Fiber laying machine
Claims (20)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102020133854.6A DE102020133854A1 (en) | 2020-12-16 | 2020-12-16 | Structural composite laminate for an aircraft component, aircraft component made therewith and aircraft |
DE102020133854.6 | 2020-12-16 |
Publications (1)
Publication Number | Publication Date |
---|---|
US20220190410A1 true US20220190410A1 (en) | 2022-06-16 |
Family
ID=81847526
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US17/550,922 Pending US20220190410A1 (en) | 2020-12-16 | 2021-12-14 | Structural composite laminate structure for an aircraft part, aircraft part manufactured with such a laminate and aircraft |
Country Status (3)
Country | Link |
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US (1) | US20220190410A1 (en) |
CN (1) | CN114633870A (en) |
DE (1) | DE102020133854A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
USD993884S1 (en) * | 2020-11-06 | 2023-08-01 | Rh Us, Llc | Aircraft exterior |
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US20100015490A1 (en) * | 2006-11-02 | 2010-01-21 | Canon Kabushiki Kaisha | Membrane electrode assembly for polymer electrolyte fuel cell and polymer electrolyte fuel cell |
KR20160140490A (en) * | 2015-05-27 | 2016-12-07 | 한국과학기술원 | Structure having energy storing capacity |
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DE102020133854A1 (en) | 2022-06-23 |
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